2RZ-3RZ-SC

1995 - 2001 SC-4RN-009-C, SC-TAC-006-C 2RZFE (2.4 L) and 3RZFE (2.7 L) Supercharger Kit

Page 1 of 21 Rev: C © TRD 09/20/02

Part Number: 00602-17620-700 series Section I - Installation Preparation Kit Contents

Item # Quantity Reqd. Description 1 1 Supercharger Assembly 2 1 Idler Pulley Assembly 3 1 Tensioner Kit 4 1 Drive Belt 5 1 Literature Kit 6 1 Support Bracket Assembly 7 1 Hose Kits

Service Parts Part # Quantity

Reqd. Description

00602-17620-730 1 per kit Drive Belt 00602-17620-019 1 per kit Idler Pulley & Bearing 00602-17620-725 1 per kit Tensioner with Pulley

Conflicts

None

Color Applicability / Trim Level

Par

t Num

ber

Vehicle

2.4-L, 2RZFE 2.7-L, 3RZFE

General Applicability

1995-1999 All 2RZFE, 2000 Fed Emission Spec. 2RZFE 2000 Cal Emission Spec. 2RZFE, 2001 All 2RZFE 1995-1999 All 3RZFE, 2000 Fed Emission Spec. 3RZFE 2000 Cal Emission Spec. 3RZFE, 2001 All 3RZFE

Legend

STOP STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury CRITICAL PROCESS: Proceed with caution to ensure a quality installation. These points will be audited on a completed vehicle installation GENERAL PROCESS: This highlights specific processes to ensure a quality installation. These points will be audited during the accessory installation TOOLS & EQUIPMENT: This calls out the specific tools and equipment required for this process


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A. Preparation:

1. Before you begin, TRD recommends that you thoroughly clean the engine and engine compartment. If you don’t, grease

buildup on parts could become dislodged during the procedure and fall into the engine.

2. Make sure the engine has cooled fully before you begin.

3. To help you later, you might want to draw diagrams of your engine’s vacuum hose routing before you disconnect

anything. However, some of the vacuum connections on your stock air intake chamber may not be the same as those on

the supercharger. Study and closely follow the vacuum diagrams for your specific application included on pages 18 –

20.

4. The TRD supercharger kit has been designed to reuse most of the stock nuts and bolts. Therefore, as you remove them,

keep them with their components or label them for location. This will assure a faster, easier installation.

Recommended Tools: Basic Tools: • Basic Metric Socket, Allen & Open-End Wrench Sets • ½” Wide Masking Tape for Labeling Hardware and Parts

• Electrical Tape • A Clean Work Bench • A Parts Tray • Rags or Shop Towels Safety Tools: • Safety Goggles Special Tools: • Toyota Repair Manual (Available from Toyota, 1-800-622-2033) Accessories: • Boost gauge recommended (not included in the kit)

STOP


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B. Removal of Stock Air Inlet System and Intake Manifold

1. Disconnect the ground cable from the battery, and then

the positive cable. Remove battery from the vehicle.

2. Remove air cleaner hose w/resonator. Figure 1

3. Remove evaporative canister vacuum switched valve

(VSV) hose.

4. Remove PCV hose.

5. Remove EGR modulator and hoses. Note hose location

and routing for re-installation. Figure 2

6. Disconnect power steering idle-up connector from the

sensor and also the wiring from the intake manifold

bracket. See arrows in Figure 3.

Figure 1

Figure 2

EGR Modulator

Figure 3


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7. Remove fuel pressure regulator hose from intake air

connector.

8. Remove intake air connector. Figure 4

9. Disconnect Throttle Position Sensor (TPS) connector

from TPS in throttle body.

10. Disconnect Idle Air Control (IAC) connector from IAC

in throttle body.

11. If vehicle is equipped with EGR, then disconnect EGR

connector from EGR sensor in intake chamber.

12. Remove throttle body from intake manifold and set

aside. Figure 5

Note: If vehicle is not equipped with EGR, skip Steps

13 & 14 and proceed to Step 15.

13. Disconnect EGR feed tube at EGR valve. See “A”

arrows in Figure 6.

14. Disconnect EGR valve from intake chamber. Leave

EGR valve in place until step 22. Do not disconnect

coolant lines.

15. Remove wire harness bracket from backside of intake

chamber. See arrow “B” in Figure 6. Remove bracket

from wire harness.

Figure 4

Intake Air Connector

Figure 5

Figure 6

B

A

A


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16. Remove bolt from the upper side of the intake chamber

stay. See arrow in Figure 7. Loosen lower bolt from air

intake chamber stay.

17. Disconnect the DLC1 from the bracket on the air intake

chamber assembly. 1995-2001 vehicles only.

18. Remove the wire harness bracket for the DLC1 wiring

from the air intake chamber assembly. 1995-2001

vehicles only.

19. Disconnect the brake booster vacuum hose from the

intake chamber hose barb.

20. If your vehicle is equipped with EGR, then disconnect

EGR tube bracket from the backside of the cylinder

head.

21. Remove the 3 bolts and 2 nuts shown in Figure 8.

22. Remove the air intake chamber and gasket. On vehicles

with EGR, separate the EGR valve from the air intake

chamber as you remove the chamber from the intake

manifold runners.

23. Remove the injector wiring ground strap from the intake

manifold.

24. Remove the 2 bolts from the fuel return pipe and

disconnect the fuel return hose from fuel pressure

regulator. See Figure 9. Caution: Plug fuel return hose

so that no fuel will spill. Set pipe and hose aside.

Figure 7

Figure 8

Figure 9


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25. Disconnect wire loom clips from the intake manifold

brackets and remove the clips from the wire loom. See

arrows in Figure 10.

26. On vehicles with EGR, remove the EGR vacuum

switched valve bracket from the intake manifold.

27. Disconnect the camshaft position sensor connector. See

Figure 10.

28. Remove wire-loom bracket and clips from the wire

loom that was disconnected in Step 15.

29. Disconnect the detonation sensor connector (A), and the

crankshaft position sensor connector (B). See Figure

11. Both connectors are located next to the engine

block, and below the intake manifold.

30. Disconnect all four fuel injection connectors and set

wiring aside.

31. On vehicles with EGR, remove the EGR coolant hose

from the EGR valve. Remove only the hose that runs

down through the intake manifold runners. Plug hose so

that coolant will not leak.

32. Disconnect the fuel inlet banjo fitting from the fuel rail.

Remove both banjo washers. See Figure 12.

33. Remove the intake manifold from the cylinder head.

Clean and inspect the intake manifold gasket. You may

re-use the gasket if it has not been damaged.

34. Remove the original equipment (OE) intake manifold

chamber stay.

35. Remove the evaporative canister steel line that is

secured to the top of the radiator fan shroud and set

aside.

Figure 10

Cam Position Connector

Figure 11

A

B

Figure 12


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36. On 2000 and earlier model years, step 36 may not be

necessary. Check the power steering pressure feed hose

clearance to the supercharger by installing the

supercharger main assembly onto the cylinder head.

When installing the supercharger, the supercharger

drive pulley and snout slides under the power steering

pump return hose. If necessary, adjust the power

steering line next to the banjo fitting on the power

steering pump. See Figure 13. The steel line needs to

be parallel with the engine centerline. Caution: Adjust

carefully so the steel line will not kink. When adjusted

correctly, the rubber hose that is connected to the steel

line will have clearance to the supercharger housing and

also to the lower radiator hose.

37. Attach the new TRD supplied 2-piece chamber stay to

the engine mount with one 8mm x 25mm long flange-

head hex bolt. See arrow in Figure 14. Make sure the

L-portion of the chamber stay points towards the front

of the vehicle. Figure 14 shows the chamber stay in the

assembled position. Attach only the lower bolt in this

step. Tighten bolt finger tight.

Figure 13

Adjust line here

Figure 14


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38. Remove the radiator fan shroud for easier access to the

components in the following steps. See Figure 15.

39. Remove power steering belt including the belt tensioner.

See Figure 16.

40. Remove the power steering pump pulley. See Figure

17. Use the Toyota Special Service Tool (SST) to stop

the pulley from rotating. Remove the pulley set nut, and

then the pulley. SST 09960-10010 (09962-01000,

09963-01000)

Figure 15

Figure 16

Figure 17


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41. Remove the two bolts that secure the power steering

pump to the pump bracket. See Figure 18.

42. Install the TRD supplied idler pulley bracket to the front

of the power steering pump. See Figure 19. Use (2)

10mm x 1.25 x 100mm long bolts supplied. Both bolts

replace the OE bolts removed in Step 41. Torque bolts

to 39 N-m (29 ft-lbf).

43. Re-install the power steering pump pulley. Use the

Toyota Special Service Tool (SST) to stop the pulley

from rotating. Torque the set nut to 43 N-m (440 kgf-

cm, 32 ft-lbf).

44. Remove the bolt that secures the oil dipstick tube to the

front side of the engine. Rotate dipstick tube slightly to

the passenger side of the engine. See Figure 20.

45. If installing on the 2.7 L (3RZFE) engine, follow Steps

46 and 47, and then skip Step 48. If installing on the 2.4

L (2RZFE) engine, then skip Steps 46 and 47, and use

Step 48.

46. Remove one bolt from the water pump housing. See

arrow in Figure 20.

Figure 18

Figure 19

Figure 20


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47. Remove the 2.7-L tensioner from the box. Insert the

95mm long countersunk head bolt through the

countersunk hole in the gold bracket. The bolt head

should fit about flush with the front-side of the bracket.

Next, align the slot of the tensioner bracket to the raised

tang on the backside of the tensioner. Tighten the 10mm

x 1.5mm crush nut to 47 N-m (35 ft-lbf). Install the

TRD dynamic tensioner on the 2.7 L using two 8 x

1.25mm x 20mm long hex bolts with two 8mm washers

(Arrows A), and one 8 x 1.25mm x 95mm long hex

socket countersunk head bolt (Arrow B). See Figure

21. Leave the 8mm bolts finger tight and torque

countersunk head bolt first. Torque all bolts to 21 N-m

(16 ft-lbf).

48. Install the TRD dynamic tensioner on the 2.4 L using

one 8 x 1.25mm x 20mm long hex bolt with 8mm

washer (Arrow A), and one 8 x 1.25mm x 20mm long

hex socket countersunk head bolt (Arrow B). See

Figure 22. Leave the 8mm bolt finger tight and torque

countersunk head bolt first. Torque both bolts to 21 N-m

(16 ft-lbf).

49. Re-install dipstick tube to the front of engine using the

OE bolt removed in Step 44. Torque bolt to 20 N-m (15

ft-lbf).

50. If your vehicle has eight round intake ports in the

cylinder head, then proceed with steps 51 and 52. If

your vehicle has four oval intake ports, then skip ahead

to step 53.

51. The wires that connect to both the detonation sensor and

the crankshaft position sensor need to be routed below

the intake manifold. Remove the nylon split flexible

tubing around the area where the wires join the main

engine wire loom. See Figure 23. Separate the

detonation sensor and crankshaft position sensor wires

back about 6” to 8” from the original breakout point.

Use electrical tape to wrap the wires that have been split

out from the main wire loom. Re -install the nylon split

flexible tubing around the main wire loom. Use

electrical tape to secure the flexible tubing.

52. Connect the detonation sensor and crankshaft position

sensor connectors before installing the supercharger.

Figure 21

A

B

Figure 22

A

B

Figure 23

Remove cover here

Separate wires from main loom


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C. Installation of TRD Supercharger 53. Note: Please read all of step 53 before proceeding.

Before installing supercharger main assembly onto the

cylinder head, connect the 10-inch long bypass actuator

hose to the hose fitting in the intake chamber and the

bypass actuator. When installing the supercharger, the

supercharger drive pulley and snout slides under the

power steering pump return hose. See Figure 24. Before

sliding the supercharger manifold over the attachment

studs, insert the fuel line banjo fitting through the TRD

manifold between intake ports three and four. It is

easiest to do this as the manifold is being lowered into

place after the supercharger snout is in position. Use

another person if necessary to help with the fuel inlet

banjo fitting. Snug all the nuts and bolts to secure the

supercharger to the cylinder head. Start in the center of

the manifold and work outward towards the ends.

Torque fasteners to 29 N-m (300 kgf-cm, 22 ft-lbf)

54. Rotate the supercharger nose support bracket to align

the slot in the bracket with the idler bracket bolt hole.

See Figure 24. Use the supplied 10mm x 1.25 x 25mm

long hex bolt and 10mm washer to secure the nose

support bracket to the idler bracket. Finger tighten bolt.

55. Using the 8mm flange head nut supplied, secure the

upper L-portion of the chamber stay to the 8mm stud

that is in the bottom-side of the TRD intake manifold.

The stud should protrude through the slot in the

chamber stay. See Figure 25. Tighten chamber stay to

supercharger first, and then also tighten to the engine

mount. Torque: 20 N-m (200 kgf-cm, 15 ft-lbf). Finally,

torque the chamber stay 8mm through bolt and nylock

nut to 20 N-m (200 kgf-cm, 15 ft-lbf).

56. Tighten the 10mm bolt that secures the nose support

bracket to the idler pulley bracket. Torque: 41 N-m (420

kgf-cm, 30 ft-lbf)

57. Tighten the socket head cap screw to secure the nose

support bracket to the supercharger nose.

Torque: 13 N-m (130 kgf-cm, 10 ft-lbf)

58. Check both the power steering pressure hose and return

hose for clearance to the supercharger snout. Both lines

should not touch the supercharger. Adjust lines as

necessary.

Figure 24 Idler bracket bolt hole

Nose support bracket

Figure 25


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59. Reconnect the fuel inlet banjo fitting to fuel rail.

Torque: 29 N-m (300 kgf-cm, 22 ft-lbf)

60. Reconnect all four fuel injection connectors.

61. Attach injector wiring ground strap removed in Step 23

to the supercharger intake manifold using the supplied

6mm hex bolt and washer. See Figure 26. Torque:

8 N-m (80 kgf-cm, 6 ft-lbf)

Note: If your vehicle has eight round intake manifold

ports, then skip to step 64. If your vehicle has four oval

ports, then follow steps 62 and 63.

62. Route the crankshaft position sensor connector down

through the opening between intake port one and intake

port two of the TRD supercharger manifold and connect

to the crankshaft position sensor.

63. Route detonation sensor connector through the intake

manifold between ports two and three, and then connect

to the detonation sensor.

64. Reconnect power steering idle up connector. Install the

OE wiring bracket on to the supercharger stud. Torque

nylock nut to 20 N-m (200 kgf-cm, 15 ft-lbf). See

Figure 27.

65. On vehicles with EGR, remove the EGR temperature

sensor (Arrow A) and EGR modulator bracket (Arrow

B) from the OE intake chamber. See Figure 28.

Figure 28

A B

Figure 26

Figure 27 Install bracket here


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66. Check the OE intake chamber that was removed from

the vehicle. Look at the quantity and location of the

PCV/breather fitting/s that are next to the throttle body

surface. See Figure 29. Model year 2000 (2RZFE)

2.4 L intake chamber shown.

67. Check the TRD intake chamber to make sure that the

quantity and location of the PCV/breather fitting/s

match the OE intake chamber. See Figure 30. Note:

TRD intake chamber is photographed off the engine for

clarity. If the fitting/s match, then proceed with Step 68.

If the fitting/s do not match, then use the supplied

fittings to duplicate the PCV/breather fitting/s in the OE

intake chamber. Re -use the 16mm nylon washers to seal

the fittings into the intake chamb er.

68. If vehicle has EGR, install the EGR temperature sensor

(Arrow A) to the TRD intake chamber. See Figure 30.

Otherwise, install the TRD-supplied 10mm x 1.25 x

12mm long bolt. Teflon thread tape is recommended.

69. If vehicle has EGR, then proceed with Steps 70 through

75. If vehicle has no EGR, then skip to Step 76.

70. Use one of the supplied EGR gaskets and install the

EGR valve to the backside of the TRD intake chamber.

See Figure 31. Use the OE EGR valve nuts removed in

Step 14. Leave the nuts loose at this time.

71. Use the second supplied EGR gasket and connect the

EGR feed tube to the EGR valve. Again, use the OE

nuts removed in Step 13. Leave nuts loose at this time.

72. Torque EGR valve nuts: 19 N-m (195 kgf-cm, 14 ft-lbf)

Figure 31

Figure 30

A

Figure 29

One 17mm OE PCV fitting


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73. Install the supplied EGR tube heat shield under the nuts

that attach the feed tube to the EGR valve. The bend in

the shield moves back towards the EGR feed tube.

Torque feed tube nuts: 19 N-m (195 kgf-cm, 14 ft-lbf)

74. Reconnect EGR coolant hose removed in Step 31.

75. Re-install the EGR modulator bracket to the backside of

the TRD intake chamber using the OE bolt removed in

Step 65. Refer to Figure 31.

76. If the vehicle has no EGR, then use one EGR gasket,

block-off plate, and two 8 x 1.25mm flange nuts to seal

the EGR passage located on the backside of the TRD

intake chamber. See Figure 32. Torque nuts: 19 N-m

(195 kgf-cm, 14 ft-lbf).

77. Position TRD supplied throttle body gasket on to the

studs on the TRD intake chamber. Position the OE

throttle body also on the studs. Do not install the nuts or

the bolts at this time.

78. Reconnect TPS and IAC connectors to the sensors in the

throttle body.

79. Reconnect cam position sensor connector removed in

Step 27.

80. Tighten the OE nuts and bolts to secure the throttle body

to the intake chamber. Torque: 20 N-m (200 kgf-cm, 14

ft-lbf)

81. On vehicles with EGR, install the EGR modulator into

the bracket on the TRD intake chamber. See Figure 33.

82. Reconnect the brake booster vacuum hose to the hose

fitting on the side of the TRD intake chamber. See

Figure 33, Arrow “A”

83. Remove the OE fuel return pipe and hose. Disconnect

the OE hose at the hard line that is mounted on the inner

fender panel. Install the new supplied fuel return hose

using the OE clamps removed in Step 24. Route the new

hose under the supercharger.

84. Install supercharger drive belt using the TRD supplied

drive belt routing label as a guide.

85. Find a suitable area under the hood to mount the drive

belt routing label. Clean area to remove any dirt or

grease and affix label.

86. Re-install the radiator fan shroud removed in Step 38.

Figure 33

EGR modulator

A

Figure 32


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87. Re-install the steel line that was removed from the fan

shroud in Step 35.

88. Remove the cam cover bolt and sealing washer from the

rear hole on the driver side of the cam cover. See

Figure 34. Remove the sealing washer from the bolt.

Use the cam cover bolt to mount the supplied “Z”

bracket onto the cam cover. The bracket should sit on

top of the sealing washer. Tighten cam cover bolt.

89. Mount the EGR modulator VSV to the “Z” bracket. See

Figure 35. Use the OE 6mm bolt and washer removed

in Step 26. Torque bolt: 8 N-m (80 kgf-cm, 6 ft-lbf)

90. Reconnect the VSV hoses and EGR modulator hoses

per the vacuum diagram on the underside of the vehicle

hood.

91. Reconnect the PCV hose from the PCV valve to the

PCV fitting in the TRD intake chamber. See Figure 36,

Arrow “A”

92. Reconnect the cam cover breather hose to the fitting on

the throttle body. See Figure 36, Arrow “B”.

Figure 35

Figure 34

Cam cover bolt

“Z” bracket

Figure 36

A B


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93. Re-install intake air connector onto throttle body. See

Figure 37. Secure intake air connector-to-connector

bracket using two OE nuts removed in Step 2. Torque

nuts: 18 N-m (185 kgf-cm, 13 ft-lbf)

94. Re-install air cleaner hose with resonator.

95. On 1995-2001 vehicles, follow Steps 95 and 96. Mount

OE DLC1 bracket to the unused boss on the cylinder

head. See Figure 38. Use the OE bolt removed in Step

18. Torque bolt: 8 N-m (80 kgf-cm, 6 ft-lbf)

96. Slide the DLC1 onto the bracket until it locks into place.

97. On 2.4 L (2RZFE) engines with production dates of

01/95 to 08/98, skip to Step 98. On 2.4 L (2RZFE)

engines with production dates of 09/98 to present,

remove the 1/8 NPT plug in the top of the supercharger

manifold. See Figure 39. Install the supplied 1/8” brass

barb fitting into the manifold. Use Teflon pipe sealant

on the threads. Using the OE rubber vacuum hose,

reconnect the vacuum hose from the fuel pressure

regulator to the 1/8” brass barb fitting. Shorten the hose

as necessary.

Figure 37

Figure 39

1/8 NPT plug

DLC1 Bracket

Figure 38


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98. On 2.4 L (2RZFE) engines with production dates of

01/95 to 08/98 and all 2.7 L (3RZFE) engines,

reconnect the fuel pressure regulator hose to the air

connector.

99. Recheck all vacuum lines and connections for proper

placement and connections.

100. Apply the premium fuel stickers to the fuel gauge and

fuel filler door.

101. Apply the TRD Executive Order (EO) label to the

underside of the hood. The EO label will alert state

smog inspectors that the TRD supercharger has been

certified emissions legal in all 50 states.

102. On vehicles that do not need the ¼” vacuum hose fitting

which is installed into the front of the TRD intake

chamber, remove the rubber cap from the OE intake

chamber fitting and use it to cap the TRD fitting. See

Figure 40 for TRD fitting location.

103. Use the supplied cable ties to secure any wiring or hoses

as necessary.

104. Re-install the battery.

105. Re-attach the positive cable, then the negative cable.

106. Start engine and check for any leaks. If any leaks are

found, diagnose leaks and repair as necessary.

107. On vehicles that require the Dastek ECU, disconnect the

vehicle battery and install the Dastek ECU using the

installation instructions and wiring diagrams provided

with the ECU.

108. On vehicles that do not use the Dastek ECU, the

installation is complete.

Note: In order to reach optimum performance, the

vehicle must be driven several hundred miles (usually

one to two tanks of fuel). These miles after the

supercharger installation will allow the OE ECU to fully

adjust to the additional airflow provided by the

supercharger.

Figure 40

¼” hose fitting


Page 18 of 21 Rev: C © TRD 09/20/02

D. Vacuum Diagrams


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Symptom Possible Causes Corrective Action

Idles rough, “pings” (Trouble Code P0171—Lean Code)

Lean condition—vacuum leak Check vacuum line connections for leaks and cracked ends

Review factory service manual for proper factory vacuum routing Review instructions for proper vacuum line routing

Recheck torque on throttle body bolts

Recheck the torque on the intake manifold bolts Pings during acceleration Low octane fuel

Computer has yet to adjust to superchager Insufficient fuel delivery

Use only premium fuel

Drive several hundred miles in different driving modes (not all steady-state highway cruising for example) Dirty fuel filter—replace and follow the factory diagnosis and replacement procedures Low fuel pressure—follow the factory diagnosis and replacement procedures Injector(s) clogged—follow the factory diagnosis and replacement procedures

Low boost Belt slipping

Air filter dirty

Throttle not fully opened

Check condition of belt —oily, worn, high mileage

Check/replace air filter—TRD dyno tests have shown that the TRD air filter is among the best on the market for flow and filtering charactersitcis—consider installing one now Recheck and adjust the throttle and transmission cables. Be sure that full depression on the gas pedal achieves full throttle opening at the throttle body.

Makes a moderately loud noise under full throttle—intake noise

Normal supercharger sound No remedy. Superchargers are an air pump and the pumping action is impossible without some noise.

Rattling at idle—goes away at just above idle Normal supercharger sound Slight rattle at idle is normal, but only if the noise sharply decreases at 400-500 rpm above idle

Rattling at idle—gets louder with higher rpm or louder with more boost pressure

Drive housing bearing wear or backlash Idler pulley bearing wear or excessive freeplay

Call TRD for further diagnosis Diagnose by removing belt from supercharger and running engine for less than 30 seconds. If noise continues, source of problem is not within supercharger.

Supercharger belt jumps across pulley groove Misaligned tensioner pulley or idler pulley Damaged pulleys

Check the mounting and alignment of both the tensioner pulley and also the idler pulley Be sure that the pulleys all run true—no eccentricity

Supercharger belt leaves grey/black powder on drive housing and other areas

Normal break-in residue No corrective action necessary—belt should be fully broken in after 2000 miles

Supercharger appears to leak oil from drive housing

Front seal not fully broken in No immediate corrective action is necessary—seal should be fully mated to pulley after 2000 miles. If leaking continues, contact TRD.

2RZ-3RZ-SC

Documents

power steering

18 npt plug

fuel pressure

radiator fan

oe intake

air intake

trd intake

intake manifold